Suspension sub-frame assembly

Abstract

A suspension subframe for a vehicle is disclosed comprising a plurality of metal tubes standardized for use in vehicle exhaust systems, such as those defined by 1.5 mm gauge walls, that are affixed to each other. A structural foam material, such as an epoxy-based foam, is positioned within the metal tubes. Also provided is a method for making a suspension subframe for a vehicle comprising providing a plurality of metal tubes standardized for use in vehicle exhaust systems, such as those defined by 1.5 mm gauge walls. The metal tubes are welded together in a desired shape and a structural foam material, such as an epoxy based foam, is inserted into the tubes.

1 . A suspension subframe for a vehicle, said subframe comprising: 
 a plurality of metal tubes standardized for use in vehicle exhaust systems, said metal tubes affixed to each other; and    a structural foam material positioned within the metal tubes.    
     
     
         2 . The apparatus of  claim 1 , wherein the metal tubes have a gauge of less than about 2 mm.  
     
     
         3 . The apparatus of  claim 2 , wherein the metal tubes have a gauge between about 0.9 mm and about 1.8 mm  
     
     
         4 . The apparatus of  claim 3 , wherein the metal tubes have about a 1.5 mm gauge.  
     
     
         5 . The apparatus of  claim 1 , wherein the structural foam material is selected from the group of polyurethane-based foams and epoxy-based foams.  
     
     
         6 . The apparatus of  claim 5 , wherein the structural foam material is an epoxy-based foam.  
     
     
         7 . The apparatus of  claim 1 , wherein the structural foam material is localized at specific points in the tube.  
     
     
         8 . A suspension subframe for a vehicle, said subframe comprising: 
 a plurality of metal tubes standardized for use in vehicle exhaust systems, each of said tubes defined by metal walls having a gauge of about 1.5 mm; and    an epoxy-based structural foam material positioned within the metal tubes, said structural foam material localized at predetermined areas in the tubes.    
     
     
         9 . A method for making a suspension subframe for a vehicle comprising: 
 providing a plurality of metal tubes standardized for use in vehicle exhaust systems;    welding said metal tubes together in a desired shape; and    inserting a structural foam material into said tubes.    
     
     
         10 . The method of  claim 9 , wherein the metal tubes provided have a gauge of less than about 2 mm.  
     
     
         11 . The method of  claim 10 , wherein the metal tubes have a gauge between about 0.9 mm and about 1.8 mm.  
     
     
         12 . The method of  claim 11 , wherein the metal tubes have a gauge of about 1.5 mm.  
     
     
         13 . The method of  claim 9 , wherein the structural foam material further comprises an epoxy-based structural foam material.  
     
     
         14 . The method of  claim 13 , wherein the insertion step further comprises the following steps: 
 inserting a structural foam cartridge into the metal tubes; and    allowing said structural foam cartridge to cure.    
     
     
         15 . The method of  claim 14 , wherein the curing step requires an additional polymeric material to be inserted to promote curing.  
     
     
         16 . The method of  claim 13 , wherein the insertion step is accomplished by spraying the structural foam material into the metal tubes.  
     
     
         17 . The method of  claim 16 , wherein the spraying is done at specific, localized points within the metal tubes.  
     
     
         18 . A method for making a suspension subframe for a vehicle, said method comprising the steps of: 
 providing a plurality of metal tubes, said metal tubes standardized for use in vehicle exhaust systems and having a gauge of about 1.5 mm;    welding said metal tubes together in a desired shape; and    inserting an epoxy-based structural foam material into said metal tubes.    
     
     
         19 . The method of  claim 18 , said step of insertion comprising spraying the epoxy-based structural foam material into the metal tubes at specific, localized points.